Differential Stretch Multiple-Size Cap

ABSTRACT

A cap is constructed using multiple uni-axially stretchable woven gore fabric all of which are connected to a crown portion. A single-layer headband is stretchable along a peripheral edge and at 45 degree angles to the crown portion and is connected to the lower peripheral exterior edge of the crown portion. A narrow, highly-stretchable flat band of woven material that is stretchable along the peripheral edge of the crown portion and at 45 degree angles to the peripheral edge of the crown portion is connected and stretchable to the lower peripheral interior edge of the crown portion. The headband, lower peripheral edge of the crown portion and narrow, highly stretchable flat band are then folded upward into the crown portion. These three components are then connected with a loose single-needle stitching to allow for maximum materials stretch along the peripheral axis and at 45 degree angles to the peripheral axis.

CROSS-REFERENCE TO RELATED APPLICATIONS

This non-provisional application claims the entire benefit of a provisional application entitled “Differential Stretch Multiple-Size Cap”, filed on Sep. 30, 2012 and having Ser. No. 61/707,966, wherein all the above-referenced applications were filed by the same inventor.

FIELD OF THE INVENTION

The present invention relates to caps to be worn on the head of the user, and more particularly to a multiple-size cap for wearing on a variety of head sizes and head shapes with comfort.

BACKGROUND OF THE INVENTION

The present invention relates to an improved construction of a multiple-size cap capable of fitting wearers having a range of head sizes and head shapes with comfort. In particular, the cap includes a headband with differential or non-uniform stretch across its width.

While such proposals are a step forward in the art, a need in the art still exists for caps that are capable of multiple-size use and which are comfortable in fitting not only different head sizes but also different head shapes. It is to such need that the present invention is based.

A free-size cap is described in U.S. Pat. No. 5,715,540 to Cho. In this patent, a sweatband made of a uni-axially stretchable fabric is sewn into the lower periphery of a cap crown portion constructed of a multiple-gores. The Cho reference attempts to address increased manufacturing costs associated with single-size caps, lost aesthetic appeal, and decreased comfort associated with multi-size caps. However, it only partially addresses the problem of decreased comfort. The Cho reference does not disclose or teach the use of a headband that stretches in multiple directions to accommodate not only different head sizes but also different head shapes with greater comfort and better fit.

A multi-size cap is described in U.S. Pat. No. 6,868,559 to Wong. In this patent, a headband made of a stretchable material is sewn into the lower periphery of a cap crown portion constructed of gores, at least some of which are composed of stretchable material. The Wong reference attempts to address complicated constructions of multi-size caps and decreased comfort associated with multi-size caps. However, the Wong reference does not disclose or teach a headband that stretches at 45 degree angles to periphery of the cap crown portion, thus offering different rates of expansion along the width of the headband to provide greater comfort for different head shapes as well as different head sizes. In addition, the Wong reference includes an elastic band that exerts inward pressure on the users head to ensure a snug fit. However, the Wong reference does not disclose or teach an alternative construction method and materials to preserve a snug fit while removing the constrictive nature and discomfort of the elastic band inherent in the Wong reference.

An elastically retained hat and band is described in U.S. Pat. No. 7,020,900 to Ngan. In this patent, a hat includes an elasticized band to retain the hat on the head of a wearer. The Ngan reference attempts to address comfort of use while retaining a hat on the head of a wearer by means of an elasticized headband that provides non-uniform longitudinal stretch along the headband width. However, the Ngan reference does not disclose or teach a hat that provides multiple-size use and does not provide for stretch in the crown portion thus limiting utility as a multiple-size hat. While such proposals are a step forward in the art, a need in the art still exists for caps that are capable of multiple-size use and which are comfortable in fitting not only different head sizes but also different head shapes. It is to such need that the present invention is based.

SUMMARY OF THE INVENTION

Accordingly, the present invention provides a cap capable of fitting wearers with a range of head shapes and head sizes with comfort through improved construction and components so as to allow for a differential stretch along the width of the cap headband. The present invention provides for a cap made from a crown portion constructed from multiple gores and a visor or bill connected to the crown portion. The gores forming the crown portion are composed of a uni-axially stretchable woven fabric. The present invention provides for a cap having a multi-axially stretchable single-layer headband comprised of woven material that is stretchable along the peripheral edge of the crown portion and at 45 degree angles to the peripheral edge of the crown portion is connected to the lower peripheral exterior edge of the crown portion. A narrow, highly-stretchable flat band of woven material that is stretchable along the peripheral edge of the crown portion and at 45 degree angles to the peripheral edge of the crown portion is connected to the lower peripheral interior edge of the crown portion. The headband, lower peripheral edge of the crown portion and narrow, highly stretchable flat band are then folded upward into the crown portion. The connective sewing of these three components is accomplished with a loose single-needle stitching to allow for maximum materials stretch along the peripheral axis and at 45 degree angles to the peripheral axis, thus providing a more comfortable multiple-size cap that adjusts to both the wearer's head size and head shape.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a side view of a cap.

FIG. 2 illustrates a bottom view of the cap of FIG. 1.

FIG. 3 shows a close up view of stretchable directions of the headband of the cap of FIG. 1.

FIG. 4 shows a close up view of the stretchable directions of the narrow highly stretchable flat band of the cap of FIG. 1.

FIG. 5 is a cutaway cross sectional view of the connective sewing and arrangement of the headband, the narrow highly-stretchable flat band, and the peripheral edge of the multi-gore fabric shell crown.

DETAILED DESCRIPTION

A cap capable of fitting wearers having a range of head sizes and shapes with comfort includes fabric sections which form a multi-fabric section shell crown id disclosed. The fabric sections are composed of a uni-axially stretchable woven material capable of being stretched elastically only along one axis, the stretch axis. The material in the cap is oriented so that the direction of the stretch axis is oriented to match the circumferential direction of the outside of the cap around the head of a wearer as more fully described below.

Referring to FIG. 1 there is shown a top view of the cap which is constructed using a multi-gore fabric shell crown portion 101 comprised of individual uni-axially stretchable fabric gore sections 102 connected by sewing along the seams 103 between the uni-axially stretchable fabric gore sections 102.

Turning now to FIG. 2 there is shown a bottom view of the cap showing the individual uni-axially stretchable fabric gore sections 102. The gore sections 102 are connected by sewing along the seams 103 between the uni-axially stretchable fabric gore sections 102 and the orientation of a uni-axial stretchable axis 107 of the uni-axially stretchable fabric gore sections 102. A headband 104 is connected to the lower peripheral edge of a crown portion 101, as shown in FIG. 2.

FIG. 3 shows a close up view the stretchable directions of the headband 104 in its (longitudinal) peripheral direction 105 when positioned at the periphery of the crown portion 101, as shown in FIG. 2 and at 45 degrees 106 to the peripheral direction. More specifically and as illustrated in FIGS. 2 and 3, the head band is a flat woven material, woven as a multi-axially stretchable fabric that is stretchable along its longitudinal axis, and is oriented along the peripheral (circumferential) edge of the crown portion, and is also stretchable in a direction 45 degrees to its longitudinal axis, thereby allowing for variable amounts of longitudinal stretch at different points along the width of the headband 104. The headband 104 is visible and allows for more than one stretchable direction of the headband. More particularly, at varying 45 degrees to the peripheral axis 106 and additionally varying in the (longitudinal) peripheral direction 105 according to a user's head shape and, as shown in FIG. 3.

FIG. 4 shows a close up view of the stretchable directions of the narrow highly stretchable flat woven fabric band 108, in its (longitudinal) peripheral direction 109 when positioned at the periphery of the crown portion 101, shown in FIG. 1 and at 45 degrees 110 to the peripheral direction. Once again, this narrow highly-stretchable flat band 108 is woven as a multi-axially stretchable fabric stretchable along its longitudinal axis and is positioned along the peripheral (circumferential) edge of the crown portion. The flat band 108 is also stretchable at a direction 45 degrees (e.g., 110) to its longitudinal axis.

FIG. 5 is a cutaway cross sectional view of the sewed configuration and arrangement of the headband 104, the narrow highly-stretchable flat band 108 and the peripheral edge of the multi-gore fabric shell crown which is comprised of individual uni-axially stretchable fabric gore sections 102 connected by sewing along the seams between gore fabric sections 103. Loose single-needle stitching 109 provides the connective sewing to secure the pieces together and allow for stretch ability of all pieces.

Referring once again to FIG. 5, more specifically, the highly-stretchable woven flat band 108 fabric is positioned with its outer edge aligned with the lower peripheral edge of the crown directly adjacent to and positioned to cover an inner surface of the lower peripheral edge of the crown portion, while the flat woven headband is positioned with its outer edge aligned with an inner edge of the flat band 108 directly adjacent to and positioned to cover the outer surface of the lower peripheral edge of the crown portion and then the flat band 108, the peripheral edge of the crown portion, and the headband 104 being sewn together. The headband 104, lower peripheral edge of the crown portion and the narrow highly stretchable flat band 104 are then everted or folded upward into (inside) the crown portion.

The connective sewing of these three components is accomplished with a loose single-needle stitching to allow for maximum materials stretch in the peripheral (circumferential) direction and for stretch in directions at 45 degree to the peripheral (circumferential) direction. This configuration provides a cap headband to accommodate a wide variety of wearer's cap head dimensions and shapes which as designed is easily manufactured and comfortable for the wearer. It should be understood that the described cap configuration allows and wearer to automatically adjust to his/her range of head circumferences and different head shapes while simultaneously allowing for different rates of expansion (stretch) along the width of the headband. Lastly, the afore-described cap configuration provides a differential stretch capability thereby allowing a comfortable custom fit for each wearer's head shape and size.

While the preferred embodiment of the present invention comprises a visor or cap portions, other embodiments without a visor or cap are also understood to be within the scope of the invention.

While the present invention has been described with regards to particular embodiments, it is recognized that additional variations of the present invention may be devised without departing from the inventive concept. 

What is claimed is:
 1. A multiple-size cap comprising: a crown portion comprised of multiple fabric gores of uni-axially stretchable fabric and a visor or bill connected to the crown portion; and a flat woven headband stretchable along its longitudinal axis and at directions of 45 degrees to its longitudinal axis loosely sewn at one edge to the peripheral edge of said crown portion of said cap; and a narrow, flat woven band stretchable in along its longitudinal axis and at directions of 45 degrees to its longitudinal axis loosely sewn to a peripheral edge of said crown portion of said cap.
 2. A multiple-size cap of claim 1 having an appearance of being fitted while actually being adjustable to comfortably fit a range of head sizes and head shapes.
 3. A multiple-size cap of claim 1, wherein said headband is composed wholly or partially of moisture-absorbing or moisture-wicking flat woven material stretchable in along its longitudinal axis and at directions of 45 degrees to its longitudinal axis sewn to a peripheral edge of said crown portion of said cap.
 4. A multiple-size cap of claim 2, wherein said headband is composed wholly or partially of moisture-absorbing or moisture-wicking flat woven material stretchable in along its longitudinal axis and at directions of 45 degrees to its longitudinal axis sewn to a peripheral edge of said crown portion of said cap. 